In the food packaging industry, innovation is increasingly driven by collaboration between specialised companies. This shared vision led to the project developed by Resaplast and Campetella, an Italian company internationally recognised for its expertise in industrial automation.
The two Italian companies combined their manufacturing and technological expertise to develop Modula Food Pack (Modula FP), a robotic cell designed to integrate post-moulding operations into a single system. From the automatic insertion of IML labels into the mould to quality control through machine vision and final case packing, every stage is fully automated. The system delivers extremely fast production cycles, compatible with the speed requirements of the food packaging sector, while maintaining a compact footprint.
One of the system's most distinctive features is its optical inspection capability. Thanks to two high-resolution cameras, parameters such as dimensional and geometric accuracy, correct label application, surface defects, and micro-imperfections that are not always detectable by the human eye can be inspected automatically, enabling non-conforming items to be identified and rejected before they proceed further along the production line.
While final inspection was once entrusted to visual checks performed by operators, today every single package undergoes a fully automated 360-degree inspection process. This approach ensures a consistent and standardised level of quality across the entire production output.
Automation also extends to the case packing stage, which is managed by a robotic system capable of arranging products with precision, continuity, and repeatability. This significantly reduces manual intervention, allowing operators to focus on line supervision, increase the number of presses under their control, and improve the overall efficiency of the production process. At the same time, higher moulding speeds contribute to increased production capacity.
Following the installation of the first prototype at the Resaplast production facility, the continuous exchange between the two companies enabled the system to be further refined through a series of functional improvements. These enhancements have contributed to the development of increasingly efficient, reliable, and optimised versions of the technology.
One of the most significant upgrades is the implementation of predictive maintenance-oriented tools. In addition to the two cameras dedicated to quality control, the system also incorporates a third camera specifically designed to monitor internal operations. Any production stoppage is automatically recorded, allowing technicians to accurately identify the cause of anomalies and schedule targeted maintenance interventions. The long-term objective is to progressively transition towards a fully predictive maintenance model.
The synergy between Resaplast and Campetella is a concrete example of how complementary expertise can translate into innovative technologies capable of improving production processes and responding to the evolving needs of the market. A true Made in Italy collaboration model, set to define new standards of automation and excellence within the food packaging industry.
